A modular plug is disclosed as having a housing, a wire manager, a load bar, and a rear component each configured to snap-fit together to assemble the modular plug. The wire manager has a plurality of channels axially positioned about a central axis, each channel being configured to receive a twisted pair of wires from a telecommunications cable, and each channel having a first width and a gate having a second width smaller than the first width.
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21. A modular plug for terminating a telecommunications cable comprising:
a housing having an internal cavity;
a wire manager fitted inside the internal cavity, the wire manager having a body defining a plurality of channels axially positioned about a central axis, each channel being configured to receive a twisted pair of wires from a telecommunications cable, and each channel having a first width and a gate having a second width smaller than the first width;
a load bar fitted within the internal cavity of the housing, the load bar having an array of external grooves, each external groove being configured to receive a wire, the load bar including an internal cavity having a top surface and a bottom surface that converge into the array of external grooves; and
a plurality of wire contacts aligned with the array of external grooves.
1. A modular plug for terminating a telecommunications cable comprising:
a housing having an internal cavity;
a wire manager fitted inside the internal cavity, the wire manager having a body defining a plurality of channels axially positioned about a central axis, each channel being configured to receive a twisted pair of wires from a telecommunications cable, and each channel having a first width and a gate having a second width smaller than the first width, each channel and respective gate extending in a direction parallel to the central axis, and each gate being configured to hold a twisted pair of wires from the telecommunications cable about the central axis;
a load bar fitted within the internal cavity of the housing, the load bar having an array of external grooves, each external groove being configured to receive a wire from one of the twisted pairs of wires that passes through one of the gates of the wire manager; and
a plurality of wire contacts aligned with the array of external grooves.
23. A modular plug for terminating a telecommunications cable comprising:
a housing having an internal cavity;
a wire manager fitted inside the internal cavity, the wire manager having a body defining a plurality of channels axially positioned about a central axis, each channel being configured to receive a twisted pair of wires from a telecommunications cable, and each channel having a first width and a gate having a second width smaller than the first width;
a load bar fitted within the internal cavity of the housing, the load bar having an array of external grooves, each external groove being configured to receive a wire;
a plurality of wire contacts aligned with the array of external grooves; and
a rear component configured to fit around a protective outer jacket of the telecommunications cable and to attach to the housing, the rear component having tabs configured to snap-fit into corresponding slots in the housing, and the rear component further includes an opening; internal surfaces having at least one internal ratcheting rib; and a strain relief member having a base, sides extending from the base, and external ratcheting ribs positioned on each side, the strain relief member being configured to fit through the opening, engage the internal ratcheting ribs on the internal surfaces, and apply a compression force on the protective outer jacket of the telecommunications cable.
2. The modular plug of
3. The modular plug of
4. The modular plug of
5. The modular plug of
6. The modular plug of
7. The modular plug of
10. The modular plug of
11. The modular plug of
12. The modular plug of
13. The modular plug of
14. The modular plug of
15. The modular plug of
an opening;
internal surfaces having at least one internal ratcheting rib; and
a strain relief member having a base, sides extending from the base, and external ratcheting ribs positioned on each side, the strain relief member being configured to fit through the opening, engage the internal ratcheting ribs on the internal surfaces, and apply a compression force on the protective outer jacket of the telecommunications cable.
16. The modular plug of
17. The modular plug of
18. The modular plug of
19. The modular plug of
22. The modular plug of
24. The modular plug of
25. The modular plug of
26. The modular plug of
27. The modular plug of
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This application claims priority to U.S. Patent Application No. 62/773,792 filed on Nov. 30, 2018, the disclosure of which is incorporated herein by reference in its entirety.
In the field of data communications, communications networks typically utilize telecommunications cable lines designed to maintain the integrity of signals being transmitted via the network. Telecommunications cable lines are typically connected into port or jack terminals using connector plugs that enable the cables to be easily connected and disconnected. The cable lines are typically comprised of twisted pairs of wires surrounded by a cable jacket. Quick connect cables are often constructed by securing a connector plug to the ends of the twisted wire pairs and sliding the connector plug into a matching port terminal where it locks into place with a simple lever lock. An RJ45 type connector is one example.
Crosstalk can negatively affect signal integrity in the telecommunications cable lines. Crosstalk is unbalanced noise caused by capacitive and/or inductive coupling between parallel wires. Furthermore, existing connector plug arrangements can be difficult to terminate in the field. For these and other reasons, improvements are desirable.
One aspect relates to a modular plug for terminating a telecommunications cable. The modular plug includes a housing having an internal cavity. A wire manager is fitted inside the internal cavity, and the wire manager has a body defining a plurality of channels axially positioned about a central axis. Each channel is configured to receive a twisted pair of wires from a telecommunications cable, and each channel has a first width and a gate having a second width smaller than the first width. A load bar is fitted within the internal cavity of the housing. The load bar has an array of external grooves, each external groove being configured to receive a wire, and a plurality of wire contacts are aligned with the array of external grooves.
Each gate may include opposing sloped surfaces that are angled in converging directions with respect to the central axis. Each gate may further include opposing parallel surfaces that are substantially parallel to the central axis. In some examples, the second width of each gate is equal to or less than the diameter of a single wire from each twisted pair of wires. In some further examples, each gate is configured to hold a twisted pair of wires from the telecommunications cable in a stacked horizontal arrangement. Each channel may include at least one slit that permits each channel to flex around a twisted pair of wires.
In one example, the wire manager includes tabs configured to latch onto corresponding notches on the load bar. In another example, the wire manager includes four channels. In some examples, each channel has a circular cross-section.
The load bar may include an internal cavity having a top surface and a bottom surface that converge into the array of external grooves. The top surface and the bottom surface each include internal grooves that funnel into the array of external grooves. In one example, the array of external grooves on the load bar are parallel and are arranged in the same vertical plane. The load bar may include tabs configured to snap-fit into corresponding slots in the housing.
The modular plug may further include a rear component configured to fit around a protective outer jacket of the telecommunications cable and to attach to the housing, the rear component having tabs configured to snap-fit into corresponding slots in the housing. The rear component may further include: an opening; internal surfaces having at least one internal ratcheting rib; and a strain relief member having a base, sides extending from the base, and external ratcheting ribs positioned on each side, the strain relief member being configured to fit through the opening, engage the internal ratcheting ribs on the internal surfaces, and apply a compression force on the protective outer jacket of the telecommunications cable. The sides of the strain relief member are configured to fit around the protective outer jacket of the telecommunications cable. In one example, the base of the strain relief member has a form factor corresponding to the shape of the protective outer jacket of the telecommunications cable. In another example, the rear component further includes apertures, each aperture configured to receive a distal end of each side of the strain relief member. In another example, the rear component includes an arm configured to prevent a latching handle from being snagged.
In some examples, the housing includes a latching handle configured to secure the modular plug to a receptacle. In some further examples, the housing includes an array of slots along a leading edge, the wire contacts being received in the array of slots and being configured to electrically connect the twisted pairs of wires in the telecommunications cable to the contact springs of a telecommunications jack.
In one aspect, a telecommunications cable is terminated by the modular plug.
In another aspect, a method of terminating a telecommunications cable with a modular plug comprises: sliding twisted pairs of wires through channels of a wire manager; using gates on the channels to hold the twisted pairs of wires; straightening twisted pairs of wires; sliding a load bar onto the wires and attaching the load bar to the wire manager; trimming the wires to be flush with a distal end of the load bar; attaching a housing to the load bar; and crimping wire contacts housed inside the housing to contact the wires. The method may further comprise attaching a rear component to the housing. The method may also further comprise trimming the wires to have a predetermined length beyond the wire manager. In one example, the channels are axially positioned about a central axis of the wire manager.
A variety of additional inventive aspects will be set forth in the description that follows. The inventive aspects can relate to individual features and to combinations of features. It is to be understood that both the forgoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the broad inventive concepts upon which the examples disclosed herein are based.
The following drawing figures, which form a part of this application, are illustrative of described technology and are not meant to limit the scope of the disclosure in any manner.
Various embodiments will be described in detail with reference to the drawings, wherein like reference numerals represent like parts and assemblies throughout the several views. Reference to various embodiments does not limit the scope of the claims attached hereto. Additionally, any examples set forth in this specification are not intended to be limiting and merely set forth some of the many possible embodiments for the appended claims.
As shown in
As shown in
Referring now to
As shown in
The body 401 includes an arm 404 that can prevent the latching handle 206 of the housing 200 from snagging or being snagged. The arm 404 may also actuate the latching handle 206 by transmitting pressure asserted onto the arm 404 to the latching handle 206 to insert or remove the modular plug 100 from a telecommunications jack. Accordingly, the difficulty of actuating the latching handle 206 of the housing 200 due to the relatively small size of the modular plug 100 is reduced or eliminated by the arm 404 of the rear component 400.
The rear component 400 further includes a strain relief member 414 that has a base 416, sides 418 extending from the base 416, and external ratcheting ribs 420 positioned on each side 418. The strain relief member 414 fits through an opening 408 in the body 401 of the rear component, and the external ratcheting ribs 420 engage and lock onto the internal ratcheting ribs 412 of the body 401. In an alternative embodiment, the strain relief member 414 and the opening 408 may be included in the housing 200.
When the strain relief member 414 is pushed downward through the opening 408, the strain relief member 414 applies a compression force on the protective outer jacket of the telecommunications cable 10. Advantageously, the strain relief member 414 can securely lock the rear component 400 onto the terminal end of the telecommunications cable 10.
In some examples, the base 416 of the strain relief member 414 includes a form factor 422. The form factor 422 can have a shape that corresponds to the exterior shape of the telecommunications cable 10. For example, the form factor 422 can have a semi-circular shape to match the exterior shape of a rounded telecommunications cable 10. Other configurations, including other shapes and sizes for the form factor 422, are possible.
The rear component 400 further includes apertures 424. Each aperture 424 can receive a distal end of each side 418 of the strain relief member 414. When the strain relief member 414 is inserted through the opening 408, the sides 418 of the strain relief member 414 fit around the protective outer jacket of the telecommunications cable 10, and the base 416 compresses the protective outer jacket of the telecommunications cable 10 onto at least a portion of the rear component 400. Depending on the diameter of the telecommunications cable 10, the distal ends of the sides 418 can be inserted through the apertures 424 of the rear component 400.
The wire manager 300 includes a body 301 having a plurality of channels 304 axially positioned about a central axis A-A.
As described above, the telecommunications cable 10 includes four twisted pairs of wires. Accordingly, when the telecommunications cable 10 is terminated by the modular plug 100, each twisted pair of wires is received by a channel 304. In alternative examples, the wire manager 300 can have a greater or lesser number of channels 304 as may be needed or desired for a particular application. For example, the wire manager 300 can define two, three, five, seven, or eight channels. Other configurations are possible.
Each channel 304 receives a twisted pair of wires from the telecommunications cable 10 at the first end 306, and each twisted pair of wires exits each channel 304 at the second end 308. Each channel 304 includes a gate 310 at the second end 308.
Each gate 310 defines a smallest dimension of each channel 304 to be substantially similar to the diameter of a single wire from each twisted pair of wires. In some examples, each gate 310 has a smallest dimension that is less than twice the diameter of a single wire. In some further examples, each gate 310 has a smallest dimension that is equal to or less than the diameter of a single wire from each twisted pair of wires.
Each gate 310 reduces the width of each channel 304 at the second end 308. For example, each channel 304 has a first width D1 at the second end 308 (see
Advantageously, the gates 310 maintain the twist and spacing between the twisted pairs of wires before the wires reach the load bar 500 and the wire contacts 110. By maintaining the twist and spacing, the wire manager 300 can reduce crosstalk between the wires inside the modular plug 100, and thus improve the performance of the modular plug 100.
Each gate 310 includes opposing sloped surfaces 312 that are angled in converging directions with respect to the central axis A-A. The opposing sloped surfaces 312 extend from the rear to the front of the wire manager 300. Each gate 310 can also include opposing parallel surfaces 314 that are substantially parallel to the central axis A-A. Accordingly, the second width D2 of each gate 310 is smaller than the first width D1 of each channel 304. In some examples, the smaller width D2 of the gates 310 can hold the twisted pair of wires.
Each channel 304 includes at least one slit 316 that permits each channel 304 to flex around a twisted pair of wires. Accordingly, in some examples, each gate 310 can hold a twisted pair of wires before the wires reach the load bar 500. In some examples, each gate 310 can hold a twisted pair of wires in a stacked horizontal arrangement.
In the examples shown in
The body 301 of the wire manager 300 further includes tabs 302 that latch onto corresponding notches 506 on the load bar 500. Accordingly, the wire manager 300 snap-fits onto the load bar 500. Additionally, a first set of form factors 322 extend from each side of the body 301 and are received by a first set of corresponding grooves 522 on the load bar 500. Also, a second set of form factors 324 extend from the top and bottom surfaces of the body 301 and are received by second corresponding grooves 524 on the load bar 500. In this manner, the wire manager 300 is received by the load bar 500 such that the channels 304 and corresponding gates 310 of the wire manager 300 are positioned inside an internal cavity 504 of the load bar 500.
The body 502 defines the internal cavity 504 that receives the wire manager 300. As described above, the body 502 includes the first set of corresponding grooves 522 that receive the first set of form factors 322 on the body 301 of the wire manager 300. Additionally, the body 502 includes the second corresponding grooves 524 that receive the second set of form factors 324 on the body 301 of the wire manager 300. Accordingly, the wire manager 300 is received by the load bar 500 such that the channels 304 and corresponding gates 310 of the wire manager 300 are positioned inside the internal cavity 504 defined by the body 502 of the load bar 500.
As shown in
Each groove in the array of external grooves 512 is sized and shaped to receive a single wire from the twisted pairs of wires in the telecommunications cable 10. As described above, each wire from the twisted pairs of wires is guided by the gates 310 of the wire manager 300 into the load bar 500, and the internal grooves 508 positioned on the top surface 514 and the bottom surface 516 of the internal cavity 504 funnel the wires into the array of external grooves 512. In the example shown, the external grooves 512 are parallel and are arranged in the same vertical plane. In other examples, the external grooves 512 are vertically offset where, for example, a first row of external grooves is positioned in a first vertical plane and a second row of external grooves is positioned in a second vertical plane, and where the first vertical plane is different from the second vertical plane. Other configurations are possible.
When the modular plug 100 is assembled, the array of external grooves 512 is configured to position each wire from the twisted pairs of wires such that each wire is aligned with a wire contact 110. In the example shown, each groove in the array of external grooves 512 is exposed (e.g., uncovered) at the front portion of the load bar 500.
A crimping tool can be used to crimp the wire contacts 110 into each wire positioned by the array of external grooves 512. Accordingly, the modular plug 100 can field terminate the telecommunications cable 10 such that each wire contact 110 electrically connects the twisted pairs of wires inside the cable to the contact springs of a telecommunications jack.
Next, the method 600 includes a step 604 of attaching the wire manager 300 to the terminal end of the telecommunications cable 10.
The method 600 further includes a step 606 of straightening the wires 710.
Next, the method 600 includes a step 608 of trimming the wires to have a predetermined length that extends outside the wire manager 300.
Next, the method 600 includes a step 610 of sliding the load bar 500 onto the wires 710 and attaching the load bar 500 to the wire manager 300.
Next, the method 600 includes a step 612 of trimming the wires to be flush with the distal end of the load bar 500.
Next, the method 600 includes a step 614 of attaching the housing 200 to the load bar 500. The housing 200 snap-fits onto the load bar 500.
The method 600 may include a further step 616 of attaching the housing 200 to the rear component 400. As described above, the housing 200 snap-fits onto the rear component 400.
Additionally, the method 600 may include a step 618 of inserting the strain relief member 414 into the rear component 400. When the strain relief member 414 is pushed downward through the opening 408, the strain relief member 414 applies a compression force onto the protective outer jacket of the telecommunications cable 10 to securely lock the rear component 400 onto the terminal end of the telecommunications cable 10.
Next, the method 600 includes a step 620 of crimping the wire contacts 110 housed inside the housing 200 to contact the wires positioned by the load bar 500.
The various embodiments described above are provided by way of illustration only and should not be construed to limit the claims attached hereto. Those skilled in the art will readily recognize various modifications and changes that may be made without following the example embodiments and application illustrated and described herein, and without departing from the true spirit and scope of the following claims.
Tobey, Shawn Phillip, Fitzpatrick, Brian J., Anderson, Timothy W., Oberski, Jeffrey Allan
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